electric drive hydro blaster jan 2016 operator’s instruction ......stock code abraptor/12emot...
TRANSCRIPT
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Jan 2016 Raptor Electric Operator’s Manual 1
Australian Pump Industries
Ref: ARAP_ELECT_VER2
Operator’s Instruction Manual
Jan 2016
Aussie Pumps
Operators must read this manual and understand it before operating this machine
Electric Drive Hydro-Blaster
Aussie Raptor
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2 Raptor Electric Operator’s Manual Jan 2016
Australian Pump Industries
TABLE OF CONTENTS
Before attempting to operate your machine please read this Instruction Manual thoroughly following all directions carefully. By doing so you will ensure safe operation of the unit and will enjoy long and trouble free service from your heavy duty water blaster.
WARRANTY COVERAGE
The Aussie Eco-Clean Raptor has a two year warranty from date of purchase. This warranty covers any defect which occurs due to faulty workmanship or material under normal use. Please keep your receipt as proof of purchase. This warranty specifically excludes the following:
Damage resulting from debris or mineral deposits contained within the water supply to the machine.
Leaking hoses when the outer cover of the hose has been abraded or the hose has been kinked.
Damage to o-rings and valves, etc. caused by the use of cleaning chemicals or compounds.
Replacement of parts damaged due to fair wear and tear.
Misuse, negligence, alteration, accident or breakage.
Failure of the machine due to lack of normal maintenance services (The owner is responsible for the performance of regular maintenance services, as specified in the Operator's Manual).
Damage and/or progressive damage caused by the failure to inform Australian Pump Industries Pty Ltd, or the closest Authorised Australian Pump Agent or Distributor, within seven days of the defect becoming apparent.
Repair or modification by an unauthorised service person.
Australian Pump Industries Pty Ltd specifically excludes from warranty responsibility any consequential loss or damage including on-site servicing, loss of time, loss of use of the machine, hire costs of a replacement machine or inconvenience..
Where possible return faulty goods to the place of purchase. No products can be returned to us without prior permission. The reason for return must be clearly stated.
N.B. Warranty is not transferable to third parties in the event of sale of the machine within the warranty period. Please note that any parts used in warranty repairs are guaranteed for a period limited by the original warranty of the parent
product.
Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a replacement or refund for a major failure and for compensation for any other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure.
The benefits under the Aussie Pump warranty are in addition to other rights under Australian Consumer Law.
Safety First Page 3
Specifications Page 3
Safety Precautions Page 5
Personal Protective Equipment Page 6
Operator’s Hand Signals Page 8
Assembly & Operating Instructions Page 9
Grit Blaster Head Set Up Instructions Page 11
Troubleshooting Page 12
Accident Reporting Page 13
Emergency Medical Information Page 14
Spare Parts List & Pump Assembly Diagrams Page 16
Aussie Hydroblaster Risk Assessment Page 18
Warnings Page 20
Daily Checklist Page 20
Monthly Service Page 20
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Jan 2016 Raptor Electric Operator’s Manual 3
Australian Pump Industries
SAFETY FIRST
WARNING: To comply with Australian and New Zealand standards, operator’s of 5000psi machines and larger need to complete operational and safety training courses and be duly certified in order to comply with Occupational Health & Safety requirements. ATTENTION OPERATOR Please read the Operating and Safety Instructions in this manual thoroughly before using your Aussie Raptor water blaster. Please note that safety procedures must be followed carefully. Non-compliance can result in severe injury or even death. SAFETY CLOTHING Wearing protective clothing is essential for the use of B-class machines (5000psi and above). Eye protection, gloves, body protection, steel capped boots and ear protection equipment are essential. For details see page 7. WATER BLASTING OPERATION While using the Aussie Predator, take special care to ensure the gun and nozzle are never pointed at any person or animals. Severe injury or death may result. For details and other warnings see page 5. BACTERIA WARNING In the event that some person or persons may be sprayed by high pressure water, it is important medical personnel be advised as unusual infections with microaerophilic organisms can occur. For details see Emergency Medical Information page 14.
SPECIFICATIONS
Performance Raptor 12 Raptor 16 Raptor 18 Raptor 21
Stock code ABRAPTOR/12EMOT ABRAPTOR-16MOT ABRAPTOR/18EMOT ABRAPTOR/21EMOT
Pump pressure psi 7,300 (500 BAR) 7,300 (500 BAR) 7,300 (500 BAR) 7,300 (500 BAR)
EWP with turbo psi 12,000 12,000 12,000 12,000
Flow lpm 12 16 18 21
Motor Phase Three phase Three phase Three phase Three phase
Power kW 4 pole, 12.5 4 pole, 18.5 4 pole, 18.5 4 pole, 21
Pump speed rpm 1450 1450 1450 1450
Pump type Penta Bertolini Bertolini Bertolini
Pump Model GHC12/50S RA 1650 RA 1850 RA 2150
Nozzle size 020 030 030 040
Accessories - Hose 10M 1/4” 1,000 BAR 10M 1/4” 1,000 BAR 10M 1/4” 1,000 BAR 10M 1/4” 1,000 BAR
Gun RL84 RL84 RL84 RL84
Lance RL800 RL800 RL800 RL800
Nozzle type Laser cut Laser cut Laser cut Laser cut
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ACCESSORY INFORMATION
Ensure that all accessories are rated to 7,300 psi (500 bar) before using with the Aussie Raptor.
Suitable accessories available from Australian Pump Industries;
1) Aussie Turbo Master turbo head CTN500-_ _ _. (1/4”M to 1/2” M nipple required to fit to lance.) Also available as a complete kit with lance, gun, nozzle & nipple to allow quick coupling to hose (CTN500-_ _ _GLK)
2) Aussie Grit blast Kit TPS450 500 bar grit blast head, 1/4” F BSP (C4700.18) Probe 580mm, 20mm hose barb (C4604.01)
Note: Available as a complete kit with lance, gun, nozzle & nipple to allow quick coupling to hose (TPS450/_ _ _GLK).
3) Aussie 500 bar gun, lance & shoulder rest. RL84 500 bar spray gun, 1/2” F BSP (MPA30540000) RL800 500 bar s/s 800mm single lance, 1/2”M (MPA30500080) RL1250 500 bar s/s 1250mm single lance, 1/2”M (MPA30500092) Shoulder rest, 300mm (MPA30501921)
HIGH PRESSURE WASH DOWN The Aussie Raptor can be used for any high pressure water blasting application in construction, mining, ship cleaning, dry docks, graffiti removal or for any other difficult task.
HIGH PRESSURE PISTON PUMPS
Your high pressure Udor pumping system is the heart of your water jetter. The pump has been specially designed to be used with cold water (max 60ºC) for high pressure wash down applications. Your high pressure Udor piston pump is designed to move a certain amount of water per revolution by its three solid ceramic pistons. High pressure is created once the pump outlet is restricted with a nozzle. All high pressure outlet connections, hosing and equipment is rated over and above the maximum operating pressures of the pump. Please do not alter any valving on your pump; altering will void all warranty. For any malfunction of the high pressure pumping system, please contact Australian Pump Industries or the Distributor you purchased the unit from. Because of safety/danger hazards with high pressure systems, only use approved high pressure hosing and components when replacing or repairing your Raptor. For guidance on this, please contact Australian Pump Industries or the Distributor you purchased the unit from. Once wash down nozzles have worn, pressure loss will occur. Replacement of nozzles is necessary to maintain constant and maximum efficiency of your Raptor. Using worn nozzles will reduce unloader valve service life.
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Jan 2016 Raptor Electric Operator’s Manual 5
Australian Pump Industries
WARNING… Do Not Alter Pressure Setting Altering the high pressure unloader device and safety valve may result in severe injury or death. Warranty will be void if any high pressure valve equipment has been altered by non-qualified staff. Over-speeding or over-pressurizing of the pump system is dangerous and can severely reduce the operating life of the machine. It may also result in injury or death!
SAFETY PRECAUTIONS - IMPORTANT 1. This blaster should only be operated by an operator who has been trained in high
pressure safety awareness.
2. Never direct the spray jet at any person or animal.
3. Never direct spray jet at any surface that may contain asbestos material.
4. Never hold a finger over the high pressure nozzle.
5. Never direct the spray jet at the machine itself or any electrical equipment.
6. After use release the pressure in the high pressure hose by operating the pistol trigger.
7. Electric cables should not be left in a position where water can come into contact with the electric cable. Always keep electrical connections dry and off the ground
8. When not in use always switch off the engine and disconnect from water supply.
9. Certain components become very hot when in use. Switch off the blaster and ALLOW TO COOL before touching.
10. Do not attempt any mechanical repair. If you have a problem with your machine contact your local dealer or Aussie Pumps service division, phone 02 8865 3500
11. Never supply any liquid other than clean water to the water inlet.
12. Never pull the high pressure hose if it has formed kinks or nooses. Never pull the hose over sharp objects.
13. Do not attempt to disconnect any hose or coupling with pressure still in the hose.
14. Do not operate the machine whilst standing on ladders, use a platform tower or scaffolding.
15. We recommend the use of personal protection equipment including safety goggles & suitable footwear.
16. The electrical power voltage must agree with the voltage specified on label on base of machine. [Note: Improper connection will damage machine and void warranty.]
17. The machine must be grounded. The unit must be wired into an appropriate power source by a licenced electrician.
18. To avoid damage to cable do not roll, crush or pull it. The power cable may only be repaired or replaced by an trained electrician.
19. Disconnect from power supply and relieve pressure to hose before attempting any work on the machine.
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PERSONAL
PROTECTIVE
EQUIPMENT
‘Wear protective clothing’’
General
Appropriate personal protective equipment should be worn where:
1. hazards cannot be otherwise prevented or suitably controlled, e.g. by
engineering or administration controls, total enclosure or substitution;
and/or
2. complete protection is essential, e.g. in some occupational environments
with uncertain levels of hazards.
The provision and use of personal protective equipment does not reduce or
replace the need for proper Occupational Health and Safety prevention
measures, such as engineering or administrative controls to be undertaken.
Recommendations of such preventative measures should always be fully
explored before considering issue of personal protective equipment. Where
personal protective equipment is issued, instruction and training should be
provided regarding its correct use and maintenance.
Head Protection. Where appropriate suitable
head protection complying with AS/NZS 1808
should be worn.
Eye Protection. Eye protection complying with
AS/NZS 1337 (adequate for the purpose and of
adequate fit on the person) should be worn at all
times when in the vicinity of water blasting
operations. Where liquid is liable to cause eye
damage, full visor and goggles are recommended.
Body Protection. All persons should wear
suitable waterproof clothing complying with AS
3765.1 or AS 3765.2 as appropriate, having
regard to the type of work being undertaken.
Liquid or chemical-resistant suits should be worn
where there is an assessed risk to health or of
injury that can be prevented by such equipment.
Hand Protection. Adequate hand protection
complying with the recommendation/s of AS/NZS
2161.2, AS/NZS 2161.3 or AS/NZS 2161.5 should
be worn when there is an assessed risk of injury
that can be prevented by such equipment.
Foot Protection. All persons should wear
appropriate occupational protective footwear
complying with AS/NZS 2210.2. A metatarsal and
lower leg guard should be used by water blasting
operators where it is assessed that the risk of foot
injury can be prevented by such equipment. AS/
NZS 2210.1 provides guidance for the selection of
footwear.
Hearing Protection. Suitable hearing protection
complying with AS 1270 should be worn at all
times when the noise levels exceed limits set by
regulatory authorities. All personnel and operators
should receive instruction in the correct use and
maintenance of hearing protectors so that noise
exposure lies within the limits as recommended by
the regulatory authority.
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OPERATOR’S
HAND
SIGNALS
‘Aussie Eco-Clean … Safety First!’
This section provides a set of hand signals for communication when carrying out water blasting operations.
Pressurise System. Thumb pointing upwards, the rest of the hand closed. From the shoulder height the arm moves up and down.
Raise Pressure. First finger pointing up, the rest of the hand closed. The hand is moved in a circular motion.
Lower Pressure. First finger pointing down, the rest of the hand closed. The hand is moved in a circular motion.
Depressure System. Form a fist. Move the arm back and forth at shoulder height.
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Jan 2016 Raptor Electric Operator’s Manual 9
Australian Pump Industries
Outlet hose connection Inlet hose connection
STANDARD EQUIPMENT Before proceeding with assembly of your new Aussie Raptor, check that all parts listed below are included.
1 Gun/lance/nozzle assemble 1 x 10m high pressure hose
HIGH PRESSURE SETTING
The high pressure pump is factory set to operate at its rated pressure. DO NOT ADJUST. Tampering with the pressure regulator will void warranty and can be dangerous.
WARNING:
If pressure drops off, check nozzle for wear. Nozzles should be replaced on a regular basis (every month for machines in regular use, every 3 months for machines used intermittently. Using the machine with the incorrect nozzle size or worn nozzle will void warranty and can be dangerous to the operator.
ASSEMBLY AND PREPARATION FOR USE Check the oil in the (A) pump With the machine on a level surface the oil level should be level
with middle of side oil plug or sight glass. Do not overfill. If necessary top up with SAE30W pump oil.
Do not mix different grades of oil as this may affect the machine's performance.
If alternative oil is used first empty out existing oil by unscrewing drain plug in bottom of machine.
NOTE: Read this handbook thoroughly and follow all directions carefully before you begin using the machine.
High pressure hose
Connect the high pressure hose to the threaded outlet fitting on the side of the machine.
Water supply hose
Use a good quality hose (not supplied) of the same diameter as the inlet on the Raptor. Connect hose to inlet fitting on pump. This connection must be tight to avoid leaks. Connect the other end of the hose to the tap, ensuring that the flow will be sufficient for the pump requirements.
NOTE: A pump filter has been fitted to prevent the ingress of grit to the pump. Ensure filter is clean before using machine. This hydro-blaster can be used with water up to 60ºC.
A
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OPERATING INSTRUCTIONS The hydro--blaster is supplied with an amperage cut-out switch. Do not adjust. Adjusting amperage cut-out switch voids warranty. SWITCHING ON MACHINE 1. Ensure power is connected.
2. Turn on water supply. NOTE: Tap should be fully open.
2. Pull the gun trigger to expel air from the system. Water will trickle from the end of the lance when air is expelled.
3. Start motor at amperage protection switch.
4. Check that there are no leaks in the line connections, pistol or power lance. Pressure begins when the pistol trigger is squeezed.
SWITCHING OFF MACHINE 1. Turn switch to OFF position.
2. Turn off water.
3. Release pressure in spray gun by pressing trigger until water only drips from the spray head.
4. Release trigger on gun.
5. Press safety latch on gun. This locks gun trigger and prevents accidental triggering.
6. Unplug machine from power point.
7. Disconnect water supply hose from machine.
CARE AND MAINTENANCE
AFTER EACH USE
If there is a danger of freezing anti-freeze should be mixed with the flush water or the machine must be completely drained. After the final flush stop the machine. DO NOT allow the machine to idle for more than 15 seconds. This is particularly important when there is a danger of freezing. Do not run for longer without water supply.
STORAGE
Store the washer in an upright position, preferably drained of water if there is a danger of freezing (or fill with anti-freeze).
SAFETY … IMPORTANT
EXCESS ATOMISED MOISTURE CAN ENTER SWITCHES & MOTOR CONNECTIONS AND OVER TIME MAY CAUSE FAILURE
KEEP THE MACHINE OUT OF MOISTURE LADEN ATMOSPHERES
WARNING .... DO NOT RUN EXCESSIVE BY-PASS
SWITCH MACHINE OFF WITHIN TWO MINUTES OF CEASING OPERATION AS EXCESSIVE BY-PASS CAN CAUSE HEAT BUILD UP IN PUMP & SUBSEQUENT DAMAGE. EXCESSIVE BY PASS
RUNNING VOIDS WARRANTY!!
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Australian Pump Industries
AUSSIE GRIT BLAST HEAD SET UP INSTRUCTIONS
(optional accessory)
Note: the Aussie Grit Blast head does not come with a nozzle. You will need a 15º Aussie Laser Cut ’M’ series nozzle that suits the high pressure blaster the kit will be used with.
1. Unwind the tail coupling and remove top of the blast head. Screw in the
nozzle to the tail.
2. Replace the tail and ensure that the tip of the nozzle is a minimum of 28mm from leading edge of body and a maximum of 36mm. The fan spray from the nozzle should be perpendicular to the sand intake tail. Mark the top side of the hexagonal coupling for reference.
3. Line up the dimple in the ceramic nozzle perfectly with the sand intake tail and hold in place with the holder. Screw down the head locking nut.
4. The fan produced by the two nozzles must be aligned.
5. Connect grit blast head to hp gun/lance and activate the gun with the high pressure blaster running. Check the fan jet leaving the nozzle is the full width of the slot. Adjust by rotating hexagonal tail coupling, ensuring that the marked side of the tail always finishes on top.
6. With the high pressure washer turned off, connect the sand hose to the sand intake tail and secure with hose clips. Secure sand blast probe to other end of the hose in the same way. The probe should be lodged into the sand bag.
WARNING: To reduce the risk of injury, always protect eyes and face with goggles and mask, and hands and arms with heavy work gloves when
spraying abrasive materials.
GRIT BLAST INSTRUCTIONS
1. Connect and open the water supply line before starting the pressure washer.
2. Squeeze the gun trigger to bleed air as normal.
3. Turn on the pressure washer and squeeze the gun trigger to activate the spray. CAUTION: Always test spray on a scrap of similar material first! The high pressure spray could damage the surface if the grit blaster is held too close.
4. To determine best distance for grit blasting, start with the spray nozzle a metre away from the surface and gradually move closer, frequently checking the surface for damage.
6. Always point the nozzle downward when not spraying. This prevents water from entering the sand supply. If water does get into the sand supply hose, remove the probe from the sand, hold the gun trigger open, and let the hose air dry. Always be sure the sand hose is dry before using.
7. Keep the sand covered to prevent the overspray from wetting the sand. Do not allow small pieces of the sand bag to fall into the sand supply. A smaller piece could prevent the flow of sand.
Min 28mm Max 36mm
Check angle of jet from nozzle
Head locking nut holder ceramic piston with dimple
Sand intake tail
7,300 psi grit blast head (C4700.18)
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MAINTENANCE, SERVICE AND SPARES Your Aussie Raptor has been designed to give you long and trouble free service. If, however, having carefully followed the instructions in this booklet, you have a problem which cannot be resolved by referring to the Troubleshooting Guide below, or if you require spare parts or servicing, contact your local dealer or Australian Pump Industries on Telephone No.: (02) 8865 3500.
TROUBLESHOOTING GUIDE
FAULT CAUSE REMEDY
Pump running normally but pressure low on installation
Pump sucking air Valves sticking, dirt in valves Unloader valve seat faulty Nozzle incorrectly sized Worn piston packing
Check water supply and possibility of air ingress Check and clean or replace if necessary Check and replace Check and replace Check and replace
Fluctuating pressure Valves worn Valves blocked Pump sucking air Worn piston packing
Check and replace Check and clean out if necessary Check water supply and air ingress at joints in suction line Check and replace
Pressure low after period of normal use
Nozzle worn Suction or delivery valves worn Suction or delivery valves blocked Unloader valve seat worn Worn piston packing Cracked pistons as a result of dry running
Check and replace Check and replace Check and clean if necessary Check and replace if necessary Check and replace if necessary Replace pistons
Pump noisy Air in suction Broken or weak suction or delivery valve spring Foreign matter in valves Worn bearings Excessive temperature of liquid
Check water supply and connections on suction line Check and replace if necessary Check and clean if necessary Check and replace if necessary Reduce temperature
Presence of water in oil Oil seal worn High humidity in air Piston packing worn
Check and replace Check and change oil twice as often Check and replace if necessary
Water dripping from under pump Piston packing worn Plunger retainer worn
Check and replace Check and replace
Oil dripping Travel plug in use on pump Oil seal worn
Replace with breather plug Check and replace
WARNING: CHECK OIL LEVEL IN PUMP REGULARLY DO NOT OVERFILL
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Australian Pump Industries
ACCIDENT
REPORTING
FOR
INDUSTRIAL
APPLICATIONS
Reporting. All accidents or injuries, whether resulting in “lost time” or “no lost time” injuries, should be recorded in accordance with the recommendations of AS 1885.1.
Incidents that result in “near misses” should also be recorded as a means of providing a record of significant incidents that have the potential to result in serious injury at the workplace, so appropriate measures can be implemented to minimise or eliminate these potential hazards.
Personal Injuries. In the event that a person is injured by the impact of a water jet, the injury caused may appear insignificant and give little indication of the extent of the injury beneath the skin and the damage to deeper tissues. Although only a small hole may be present, quantities of water may have penetrated the skin and entered the flesh and organs causing serious injury.
Medical Recommendation. If an accident occurs where pressurised water penetrates or appears to have penetrated the skin, medical assistance should be sought immediately.
Immediate First Aid. Where medical examination is not immediately possible (e.g. in remote situations), appropriate basic first aid measures should be applied and the patient observed closely until medical treatment is available.
Medical Alert Card. All operators engaged in commercial and industrial water blasting operations should carry out an immediately accessible, waterproof medical alert card. This card should:
outline the possible nature of injuries and post-accident infections that can be caused by high pressure water blasting;
provide details of immediate first-aid treatment until medical treatment can be arranged; and
provide the name or names of medicos (and contact phone numbers) who should be contacted for expert medical advice for the treatment of high pressure water blasting injuries.
In addition, the card may also:
identify the worker; and
outline medical information about the worker; e.g. blood type, allergies and conditions, such as asthma.
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EMERGENCY
MEDICAL
INFORMATION
IMPORTANT
‘Aussie Eco-Clean …
Safety First!’
Immediate hospital attention should be given to personnel who sustain equipment related injuries while operating the system. In such cases, it is vital that medical personnel be apprised of all facts relevant to such injuries. Therefore, all operating personnel should be provided with waterproof emergency medical tags or cards describing the nature of their work and the possibility of injury inherent in the use of a water blasting device. The tag or card should also bear the following standard notice:
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Jan 2016 Raptor Electric Operator’s Manual 15
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ITEM NO. DESCRIPTION RAPTOR 18 RAPTOR 21 RAPTOR 12 RAPTOR 16
A 700 BAR GAUGE AGAUGE700BAR AGAUGE700BAR AGAUGE700BAR AGAUGE700BAR
B UNLOADER VALVE (VB53) BVB53 BVB53 BVB53 BVB53
C SAFETY VALVE BVS500 BVS500 BVS500 BVS500
D Y STRAINER AYSTRAINER1” AYSTRAINER1” AYSTRAINER1” AYSTRAINER1”
E THERMAL DUMP VALVE MPA60063070 MPA60063070 MPA60063070 MPA60063070
ON/OFF SWITCH TBA TBA ASWITCHASSY25A ASWITCHASSY32ES
13” WHEEL A400016 A400016 A400016 A400016
MOTOR AT416018NR9J5MG TBA A140060T025 AT416018NR9J5MG
FRAME (if applicable) AFRAMESCERAPTOR AFRAMESCERAPTOR AFRAMESCERAPTOR AFRAMESCERAPTOR
8100 PSI GUN (RL84) MPA30540000 MPA30540000 MPA30540000 MPA30540000
SS SINGLE LANCE (RL800) MPA30500080 MPA30500080 MPA30500080 MPA30500080
HP CERAMIC NOZZLE M0124006210 M0124006310 M0124006110 M0124006210
10MTR 500 BAR HOSE A36414432109 A36414432109 A36414432109 A36414432109
O PISTON PUMP 7,300 PSI Bertolini RA 1850 Bertolini RA 2150 GHC 12/50S Bertolini RA 1650
A
E D
C
B
O
F
Replacement Parts
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Jan 2016 Raptor Electric Operator’s Manual 17
Australian Pump Industries
PUMP ASSEMBLY DIAGRAM – (GHC 12/50 ) Raptor 12
Kit No. Part Number Description
BKIT 85 606185 Piston kit
BKIT 152 606186 Valve kit
BKIT 87 606187 Brass ring kit
BKIT 88 606188 Water seal kit
1205.45 Piston (3 required per pump) price each
Breathers & Sight Glass
GHC & GHD series 162505 Breather
1603B8 Sight glass
Kit No. Description Pieces
BKIT211 Valve Cap kit 18
BKIT146 Oil seal kit 3
BKIT210 O ring & sight glass kit 10
BKIT209 Valve kit 18
BKIT228 Seal kit major 19
BKIT227 Seal kit minor 13
PUMP ASSEMBLY DIAGRAM – (RA 1650, 1850 & RA 2150) Raptor 16, 18 & 21
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C
O
N
S
E
Q
U
E
N
C
E
PROBABILITY
A B C D E
1 1 2 4 7 11
2 3 5 8 12 16
3 6 9 13 17 20
4 10 14 18 21 23
5 15 19 22 24 25
AUSSIE HYDRO-BLASTER RISK ASSESSMENT
MODELS: In line with the National Occupation Health & Safety Commission’s requirements the data below applies to the Aussie Scud range of high pressure water blaster models:
Aussie Raptor Hydro-blaster DESCRIPTION: Electric drive ultra high pressure cold water blasters designed for professional cleaning applications. MATERIAL CONSTRUCTION: Aussie Scud pressure washers are mounted on heavy duty trolley mounted frames. They consist of a quality four pole electric motor driving a 500 BAR pump. The machines are supplied with wheels for ease of portability and manoeuvrability. The machines can be supplied with hose reels and up to 45 metres of high pressure hose to increase operator convenience. RISK RANKING METHOD: Risk is the combination of the likelihood of a specific unwanted event and the potential consequences if it should occur. RISK RANKING METHOD: For each event, the appropriate probability (a letter A to E) and consequences (a number 1 to 5) is selected.
RISK RANKING TABLE: The consequences (loss outcomes) are combined with the probability (of those outcomes) in the risk ranking table to identify the risk rank of each loss event (e.g. a consequence of 3 with a probability of B yields a risk rank of 9). The table yields a risk rank from 1 to 25 for each set of probabilities and consequences. A rank of 1 is the highest magnitude or risk that is a highly likely, very serious event. A rank of 25 represents the lowest magnitude of risk, an almost impossible very low consequence event. Controls must be taken to either eliminate or minimise the risk.
PROBABILITIES: A. Common or repeating occurrence. B. Known to occur or “it has happened”. C. Could occur, or “I’ve heard of it happening”. D. Not likely to occur. E. Practically impossible.
CONSEQUENCES FOR PEOPLE: 1. Fatality or permanent disability. 2. Serious lost time, injury or illness. 3. Moderate lost time, injury or illness. 4. Minor lost time, injury or illness. 5. No lost time.
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POTENTIAL HAZARD:
Signed originator ..................................................................... Job title ..................................................................................... Date Completed ......................................................................
Hazard Yes/
No Risk
Risk
Rating Controls
Entanglement with hose
(tripping, falling)
Yes Personal injury of the
operator or bystanders
13 Warning stickers
hose reel option
Injury from high pressure water Yes Personal injury of the
operator or bystanders
4 Warning notice on blaster
Warning in Operator’s Manual,
Use of safety protection clothing (Aussie
Safe-operator)
Use of barriers to keep bystanders away
from work area
Ergonomic lifting or movement
on site,
Yes Personal injury 8 Machine decal warning about correct lifting
procedures
Operator’s Manual
Staff training
Belt failure Yes Serious injury 20 Enclosed guard must be in place
Electrocution Yes Serious injury, burns 21 Warning sticker on machine
Disconnect machine when not in use
Unsecured machine, moves
unattended
Yes Cause of accidents and/
or injury
18 Warning sticker “Secure Machine during
Operation”
Operator’s Manual
Noise Yes Hearing damage 15 Warning sticker regarding ear muffs to be
used during operation
Dislodged particles in
atmosphere
Yes Sight damage 6 Warning regarding wearing safety glasses.
Slipping on wet surface Yes Personal injury 9 Use of suitable footwear
Contact with chemical cleaners
used to clean surfaces
Yes Skin contact could result
in burns, skin irritation
etc. Fumes from some
chemicals may lead to
respiratory problems
4 Chemical cleaners to only be used as a last
resort when other methods have failed.
Areas to be kept well ventilated.
Staff to follow manufacturers’ instructions at
all times for use, storage & disposal.
Staff to wear the appropriate PPE
Respiratory protection when required
PLAN SAFE … STAY SAFE
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WARNING
OVERSPEEDING
Do not operate machine at over 1450rpm.
Over speeding can cause serious pump damage.
EXCESSIVE BYPASS
Do not run on excessive bypass. Switch machine off within five minutes of ceasing operation as
excessive bypass can cause heat build-up in pump and subsequent damage. Excessive bypass
running voids warranty.
HIGH PRESSURE SETTING
The high pressure pump is factory set to operate at its rated pressure. DO NOT ADJUST. Tampering
with the pressure regulator will void warranty and can be DANGEROUS.
CHECK NOZZLE MONTHLY
If pressure drops off, check nozzle for wear. Nozzles should be replaced on a regular basis (every
month for machines in regular use, every three months for machines used intermittently). Using the machine with the incorrect nozzle size or worn nozzle will void warranty and can be DANGEROUS to
the operator.
PRESSURE CLEANER DAILY CHECK LIST IMPORTANT:
Check pump oil level
NB. Pump oil level should be level with the middle of the side oil plug or sight glass. Do not overfill. If
necessary, top up with SAE30W oil.
Do not mix different grades of oil as this may affect the machine’s performance. If alternative oil is
used, first empty out existing oil by unscrewing drain plug in bottom of machine.
Check nozzle for wear.
Check all high pressure components for leaks:
(a) Gun/Lance. (b) HP hose. (c) All fittings.
Check water filter and clean if necessary.
Check unloader, safety valve and thermal dump for leaks.
Warning: Ensure top mounted breather plug is kept clean. Blocked breather can result in pressurisation
of the oil chamber and blown seals.
THREE MONTHLY REGULAR SERVICE
All professional machines need to be thoroughly serviced every three months. The service involved should
include the motor manufacturer’s recommendations (see separate Manual) and the following:
Change pump oil
Check filter for foreign debris.
Check unloader, safety valve and thermal dump for leaks.
Check all HP components for leaks: Gun/Lance, HP hose and all fittings.
Replace nozzles.
RELIABLE PRODUCTS … RELIABLE PEOPLE
AUSTRALIAN PUMP INDUSTRIES 7 Gladstone Road, Castle Hill NSW 2154 PO Box 6164, BHBC NSW 2153
Ph (02) 8865 3500 Fx (02) 9894 4240